Abuse-proofing a 525

**Taz** · 19th October 2010, 19:19

I just zip tied a couple of bits of inner tube to the radiators.

**Ocean1** · 19th October 2010, 19:22

Originally Posted by CrazyFrog

Here you go all you 525 owners, I had a nice little ride this week.....

http://www.advrider.com/forums/showt...4#post14271924

Bastard.

Maybe next year I'll take the 525 to the Burt. This year I'm commited to taking the Buell.

I wonder...

**Ocean1** · 19th October 2010, 19:29

Originally Posted by Taz

I just zip tied a couple of bits of inner tube to the radiators.

Good. I like simple. Stops me spending stupid amounts of time re-inventing the wheel.

Thing is... I got some double sided tape, might try cutting a couple of strips of rubber slightly thicker than the channel in the outer rad frame and temporarily fitting them into the channel with the glue gun. Could apply some tape to the rubber and then spread the tank a tad and slip it on and lean on the shrouds to fix the tape. That'd give the radiators some forward / aft support too.

**Taz** · 19th October 2010, 20:01

All that will cut into your drinking time ya know.......

**Ocean1** · 19th October 2010, 20:16

I have straws. Just gota crush the ice really really small.

PS: do I have to empty the new tank before I attempt to correct some slight scratches with a propane torch?

**NordieBoy** · 20th October 2010, 06:43

Originally Posted by Ocean1

PS: do I have to empty the new tank before I attempt to correct some slight scratches with a propane torch?

Depends. Do you have a video camera?

**Ocean1** · 31st October 2010, 20:32

Whelp, I spent several hours trying to chuck the beastie off the hills of Te Awaiti Station, (on the SE Wairarapa coast) today. What a splendid machine, intermediate tracks to be sure, (with limited oportunity to crash and burn properly) but what a pleasure to punt such a wonderfully capable machine around such magnificient country.

Still need to sort the zorst, and possibly an oil cooler, but if it's even passable on the road for 4 hours or so I rekon it'll do me.

*Giggles*

**Ocean1** · 17th November 2010, 20:30

This dude here: http://www.trademe.co.nz/Browse/List...68&permanent=0 has a good deal on a set of wheels.

And I'm reasonably sure they'll fit an '04 beastie. Any advance on reasonably sure?

Anyone?

**Taz** · 17th November 2010, 21:15

Says they'll fit from 03 onwards in the ad.

**cooneyr** · 17th November 2010, 21:19

I can't actually help but doing some reading on axle diameters would be good start. If the same pretty good chance spacers will be OK and even if not then use your current spacers and change the seals.

**Ocean1** · 18th November 2010, 09:57

Originally Posted by Taz

Says they'll fit from 03 onwards in the ad.

Yeah, and they list 125 through to 530, but NOT a 525. I reckon it's a simple omission on the manufacturer's part.

Originally Posted by cooneyr

I can't actually help but doing some reading on axle diameters would be good start. If the same pretty good chance spacers will be OK and even if not then use your current spacers and change the seals.

It's got custom spacers on it anyway, I made them from 316 to replace the fucked OE ones. If spacers is all there is to worry about I'll have 'em, I was more worried about basic hub dimensions and / or rim offset etc.

I'll call TSS, they orta have the part No's to hand...

Cheers guys.

**Ocean1** · 18th November 2010, 11:40

Same part No's. Guess that's pretty conclusive.

**Ocean1** · 9th January 2011, 20:23

I've been abusing the 525. I've been trail riding. Nothing dramatic.

Anyway, the whole black plastic rear inner guard/taillight/numberplate/indicator assembly flapped around so hard it's falling apart. The plate gets continually bent forwards at the ends, fuckt if I know how that happens but teh plate's fuct now.

Anyone got the final, definitave fix? Or should I just get used to the idea that I've got 15min of changes to make before I hit the dirt. Guess I could make that easier with a couple of more strategically placed plugs...

Apart from that she's a ripper.

**CrazyFrog** · 9th January 2011, 20:41

Originally Posted by Ocean1

I've been abusing the 525. I've been trail riding. Nothing dramatic.

Anyway, the whole black plastic rear inner guard/taillight/numberplate/indicator assembly flapped around so hard it's falling apart. The plate gets continually bent forwards at the ends, fuckt if I know how that happens but teh plate's fuct now.

Anyone got the final, definitave fix? Or should I just get used to the idea that I've got 15min of changes to make before I hit the dirt. Guess I could make that easier with a couple of more strategically placed plugs...

Apart from that she's a ripper.

Same thing happened with mine, that tail piece is too long for trail riding, fine on gravel, but as soon as terrain gets rough, it bounces all over the place. My plate got so bent it started breaking away from the mounting bolts. I've seen a new 530 do the same, it bounced around so much it broke the mounting tabs off the underside of the tail piece.

I got hold of one of the short KTM enduro tail lights, and mounted my plate on that, which stops most of the stupid tail piece flexing. I will reinforce the number plate soon with a backing plate made of carbon fibre to protect the number plate more (alloy aheet would also do).
Just remember to switch the original tail piece back when you get a WOF, as the short enduro light doesn't have the white light for the number plate.

Yes, the best solution is take it off completely if you're doing real trail riding and trailering the EXC to your ride location. You will also save those $60 indicators from bouncing off too.